Pouch forming mold configuration, and method

ABSTRACT

A mold configuration for forming a pocket in a film comprising: a film support surface; a perimeter edge at said film support surface; wall surfaces inward of the perimeter edge defining a mold cavity; the wall surfaces including transition wall surfaces extending to a bottom wall surface; and a plateau surface inward of the perimeter edge. In one form, the perimeter edge includes sharp corner profile perimeter edge portions defining at least one sharp corner profile. A method of forming a pouch, includes using the disclosed mold configuration.

This application claims priority, pursuant to Title 35 USC Sec. 120 toU.S. non-provisional application Ser. No. 15/670,794, entitled “PouchForming Mold Configuration, Method and Pouch, filed Aug. 7, 2017, which,in turn, claims priority pursuant to Title 35 USC Sec. 119(e) to U.S.Provisional Application Ser. No. 62/372,050, filed Aug. 8, 2016, andU.S. Provisional Application Ser. No. 62/410,456, filed Oct. 20, 2016,the entire contents of which are hereby incorporated by reference hereinas if fully set forth.

TECHNICAL FIELD

This disclosure relates generally to a forming system for makingflexible, polymeric pouches containing a consumable product componentfrom continuous webs of film. More particularly, it relates to theapparatus and method of forming and filling pouches of unique shape andto the resultant pouches.

Flexible pouches made of polymeric film and filled with a consumableproduct are commonly produced on equipment having an array of pouchforming, mold configurations. These pouch forming mold configurationsare often incorporated into a rotating drum, or axially movable platen.Examples of such forming, filling and sealing systems include U.S. Pat.No. 3,218,776, issued Nov. 23, 1965 to Charles E. Cloud, and U.S. Pat.No. 9,162,413, issued to Cloud Packaging Solutions, LLC, the entirecontents of which are hereby incorporated herein by reference as iffully set forth herein. Other examples include U.S. Publication No.2014/0154350 and U.S. Pat. No. 8,662,880.

BACKGROUND

Machines or systems are known for forming flexible sealed pouches orpackages containing a consumable product. Such pouches may be made fromtwo continuous films in which a first or base film is vacuum formed todefine a pocket to be filled with one or more products or materials andsubsequently closed by a second or lid film. Some more recentconfigurations include multiple compartment pouches and pouches in whichmore than two films are employed. Particularly suitable applications forflexible packages from water soluble film, such as polyvinyl alcohol(PVA) involve manufacture of individual dosage pouches of laundrydetergent and/or dish washing detergent, though other commercialapplications are also known.

The nature of the forming process, heating a polymeric film and drawingthe film into mold configurations defining cavities or depressions inthe film support surface necessarily stretches the film in certain areasto conform with the mold cavity profile. This reduces the originalthickness in areas of stretch with a resultant film weakening. It istherefore common practice to design the mold configurations with smoothtransition sections having large radii corners between adjoining wallportions to minimize excessive localized stretch and consequent strengthreduction.

Moreover, the accepted processing limitation established by filmsuppliers and followed by pouch manufacturers is that a given filmtypically should not be stretched to more than twice its pre-formingarea. That is, the surface area of unformed film overlying a moldconfiguration cavity should not be expanded to more than twice thisoriginal area.

Heretofore, efforts to provide sharp corner profiles in flexible poucheshave been limited to low volume profiles utilizing gradually sloped moldsurfaces. This approach has had limited application because it limitsthe internal volume of the pouch, or increases its overall size, leadingto increased cost in film material and processing complexity. Suchprofiles have heretofore been limited to secondary or ancillary pocketsaffixed to a main pouch made under traditional forming guidelines.Moreover, these secondary or ancillary pockets require an additionalfilm layer further increasing overall material cost and processingcomplexity.

Thus, with known systems, it was not possible to produce pouches fromtwo film layers with sharp definition corner profiles and adequatevolume capacity in an acceptable pouch size. The present disclosureprovides apparatus, mold configurations and methodology to producepouches with sharp corner definition, which will satisfy the previouslyunfilled need in the industry. It also provides a simplified approach toforming and filling any shape pouch of polymeric material.

SUMMARY

A mold configuration for forming a pocket in a film comprising: a filmsupport surface; a perimeter edge at the film support surface; wallsurfaces inward of the perimeter edge defining a mold cavity; the wallsurfaces including transition wall surfaces extending to a bottom wallsurface; and a plateau surface inward of the perimeter edge. In one formthe perimeter edge includes sharp corner profile perimeter edge portionsdefining at least one sharp corner profile.

A method of forming a pouch having at least one sharp corner profile,using a mold configuration for forming a pocket in a film comprising: afilm support surface; a perimeter edge at the film support surface; wallsurfaces extending inward of the perimeter edge defining a mold cavity;the wall surfaces including transition wall surfaces extending to abottom wall surface, the perimeter edge includes sharp corner profileperimeter edge portions defining at least one sharp corner profile; anda plateau surface inward of the sharp corner profile perimeter edgeportions; the steps comprising: supporting a base film on the filmsupport surface overlying the mold configuration; applying a vacuum tothe mold configuration to cause the base film to form a pocketconforming to the shape of the mold configuration; filling the pocketwith at least one product component; adhering a lid film to the basefilm laterally of the perimeter edge of the mold configuration.

A pressurized product containment pouch of polymeric film, comprising: abase film defining a pocket portion, a lid film defining a lid portion,the films joined about a perimeter seal seam defining a hollowcontainment chamber containing a product under pressure, the pouchperimeter seal seam including: at least one sharp corner profilecomprising straight or slightly curved seal seam portions meeting at anintersection or vertex to form an angle.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a known flexible containment pouchconfiguration.

FIG. 2 is a cross-sectional view of the pouch of FIG. 1 taken along theline 2-2 of FIG. 1.

FIG. 3 is a cross-sectional view of the pouch of FIGS. 1 and 2 at aninterim stage of manufacture.

FIG. 4 is a perspective view of a known mold configuration for a pouchforming drum to produce the pouch of FIGS. 1-3.

FIG. 5 is a schematic view of an exemplary rotary form, fill and sealmachine for making pouches, as described herein.

FIG. 6 is a perspective view of a mold configuration in accordance withthe present disclosure.

FIG. 7 is a sectional view of the mold configuration of FIG. 6 taken online 7-7 of FIG. 6.

FIG. 8 is a top view of a flexible containment pouch made with the moldconfiguration of FIGS. 6 and 7 in accordance with the disclosure.

FIG. 9 is a sectional view of the pouch of FIG. 8 taken along the line9-9 of FIG. 8.

FIG. 10 is a sectional view of the pouch of FIG. 8 at an interim stageof the process.

FIG. 11 is a top plan, schematic, view of the mold configuration of FIG.4.

FIG. 12 is a top plan, schematic, view of the mold configuration inaccordance with the disclosure illustrated in FIGS. 6 and 7.

FIG. 13 is a perspective view of a mold configuration in accordance withthe disclosure for making another flexible containment pouch inaccordance with the disclosure.

FIG. 14 is a containment pouch made employing a prior art moldconfiguration.

FIG. 15 is a top view of a pouch made in accordance with the disclosurein the mold configuration of FIG. 13.

FIG. 16 is a perspective view of a multi-chamber flexible containmentpouch made in accordance with the disclosure.

FIG. 17 is a top view of the multi-chamber pouch of FIG. 16 made inaccordance with the disclosure.

FIG. 18 is an end view of the multi-chamber pouch of FIGS. 16 and 17made in accordance with the disclosure.

FIG. 19 is a perspective view of a mold configuration in accordance withthe disclosure for making the flexible multi-chamber containment pouchof FIGS. 16-18.

DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENTS

Turning now to the drawings, FIGS. 1-3 are illustrative of a knownflexible containment pouch 100 formed by joinder of two polymeric films.FIG. 4 is illustrative of a conventional mold configuration 120 forproducing the pouch of FIGS. 1-3.

The films could be water soluble polyvinyl alcohol, though other filmscould be used. The films used are “soft” and form “soft” blisters oncethermoformed from PVA, polyethylene, or other suitable polymeric film.For such soft types of film, this disclosure provides the means to formpouches with sharp corner profiles, without undo thinning of the filmthat could compromise strength of the pouch film, possibly causingleakage.

Typical film thicknesses for soft blister pouches are 0.001 inch″ (inch)to 0.004″ (inch) thick. The formed stock, sometimes called the base filmis typically around 0.003″ (inch) thick and the lid stock or lid film istypically thinner, usually around 0.002″ (inch) thick, though thesethicknesses not requisite for the principles of this disclosure. Itshould be understood that the pouch and apparatus of FIGS. 1-5 aremerely exemplary of known technology and are not limiting of thedisclosure.

Referring to FIGS. 1-3, pouch 100 includes a base film 102 and a lidfilm 104 joined along a sealed interface 106. It defines a hollowinterior volume containing a product component 110, in thisillustration, a liquid composition. The pouch 100 is generallyrectangular with a hollow volume defined by a sealed perimeter seal seam111. Perimeter seal seam 111 includes, generally, straight perimeterside seal seam portions 112 joined by corner seal seam portions 114defined by a generous radius, for example, ⅜″ (inch).

FIG. 5 is a schematic representation of a rotary pouch forming apparatusor system suitable for forming a plurality of the pouches 100 depictedin FIGS. 1-3, pouches 200 depicted in FIGS. 8-10, or pouches depicted inFIG. 14, 15 or 16-18, all as discussed further below. The pouch formingapparatus is generally similar to that disclosed in aforementioned U.S.Pat. No. 3,218,776. Pouches 100 could, however, also be produced on amoveable platen, or other suitable machine.

A base forming drum 119 includes multiple rows of mold configurations120 to produce multiple pouches simultaneously. Typically, the rotarydrum 119 is formed of a plurality of long bars 121 supported on a wheeland defining an outer smooth film support surface 122. Each bar 121includes multiple mold configurations 120, one of which is seen in FIG.4, extending inward of the drum from smooth film support surface 122along a perimeter edge 126. “Mold configuration” referred to herein, isa configuration of surfaces forming a void or cavity to receive thevacuum formed base stock film.

In this disclosure, for ease of description, the term “inward” meansfrom the drum smooth film support surface 122 toward a bottom surface ofthe cavity of a mold configuration. “Outward” means in the oppositedirection. “Laterally” means along the smooth film support surface 122,away from the perimeter edge of a mold configuration in that surface.Also, in reference to the film or web, “longitudinally” means along thelength of the web material. “Transversely” means across the web or filmfrom edge-to-edge.

The pouch forming apparatus additionally includes a vacuum system 130, aheater system 140, a product feed mechanism 150, a wetting system 160, asealing system 170, a cutting system 180, and rolls of material thatsupply base film 102, and lid film 104.

Vacuum system indicated generally at 131 in FIG. 5, includes conduits132, operatively connected to each mold configuration 120 to create avacuum to draw a portion of the base film 102 into the mold cavities toform pockets 108, seen in FIG. 3, in base film 102. Such a vacuum systemis well known in the art. A drive system (not shown) is operativelyconnected to the base forming drum 119 to rotate the drum continuouslyin direction “A.”

The heater system 140 is depicted as a rotatable base film heater roller142 positioned adjacent the base forming drum 119. It includes aninternal element to heat the base film 102 prior to it contacting thesmooth film support surface 122 of base forming drum 119 or being drawninto mold configurations 120 to form pockets 108. The heater system 140may be configured as a cartridge-type heater within the base film heaterroller 142 but other types of heaters, either internal or external to aroller, may be used if desired. In a typical method of thermoforming,for example, PVA or similar film, on a rotary drum form fill and sealpouch machine, the film is heated to a range of 140° F. to 400° F.depending on film thickness, type of film and other well-knownoperational parameters.

A product feed mechanism 150 is positioned generally adjacent the baseforming drum 119 to supply one or more product components into eachpocket 108 as the pockets, together with base film 102, move along withthe outer smooth film support surface 122. Product feed mechanisms 150are well known in the art and may take any known form. Such mechanismsmay be configured to feed any desired type of composition, number orcombination of individual products and/or materials including a liquid,a gel, a solid, a powder, a paste or wax-type products, pills, tablets,or even other pouched products.

A supply roll of continuous film material provides the lid film 104. Thelid film 104 is aligned with the base film 102 so as to come intooverlying contact with the base film 102 after the filling of thepockets 108 in the base film. The illustrated lid wetting system 160helps create a strong seal between the base film and lid film. It ispositioned adjacent the lid film 104 at a position upstream of where thelid film 104 seals the base film 102 at the base forming drum 119. Thelid wetting system 160 may apply a solvent to the lid film 104 toincrease its tackiness to assist in adhering the lid film 104 to thebase film 102. To do so, the solvent may be provided through a wettingreservoir 162 to a wetting roller 163 that engages the lid film 104. Ininstances where the base film 102 and lid film 104 are formed of apolyvinyl alcohol material, the solvent for the lid wetting system 160may be water.

A sealing system 170 having a sealing roller 172 is positioned in closecontacting relation to the smooth film support surface 122 of baseforming drum 119. Lid film 104 passes around sealing roller 172 and isurged into sealing contact with base film 102 to urge the contactingsurfaces of base film 102 and lid film 104 into adhering, sealedrelation. In this regard, the sealing roller 172 is mounted such that itapplies pressure to the overlying films to perfect the sealingrelationship. Sealing roller 172 may include an outer layer 173 formedof material that is deformable, such as a rubber or similar material,though this is not essential. Typically, this material has a thicknessof about one-half inch (½″) and a durometer of about 60, though thesevalues may vary. The material, and the pressure exerted on the overlyingfilms, assures affective contact of base film 102 and lid film 104 alongthe sealed interface 106. Of course, depending on the film material, itis also known to use heat, for example, ultrasonic welding or othersimilar process to seal the lid film and base film together to form acompleted pouch.

A cutting system 180 may be positioned after, or downstream from thelocation at which the base film 102 and the lid film 104 are securedtogether. Cutting system 180 includes a series of transversely spacedapart slitting knives 181 that engage the combined films 102 and 104 toslit the films in a longitudinal direction along the outer surface ofbase forming drum 119 to create a plurality of longitudinal strips thateach include a plurality of pouches 100. A rotary knife 182 may bepositioned after, or downstream from the slitting knife 180.

Referring to FIG. 5, in operation, a base film 102 such as a polyvinylalcohol film is fed from its supply roll and passes around rotatablebase heater roller 142 and is heated to a temperature sufficient toallow thermoforming. In one example, the temperature may beapproximately 160° F. but other temperatures may be utilized dependingupon the material of the base film 102, its thickness, and othermanufacturing characteristics.

The heated base film 102 is routed over the smooth film support surface122 of long bars 121 of base forming drum 119. A vacuum applied to eachmold configuration 120 deforms or stretches the base film 102 and pullsa portion of the heated film 102 into the mold cavity of each moldconfiguration to form base pockets 108 of the pouches 100. Pockets 108define a fill volume to receive the product component. As the baseforming drum 119 is rotated and the base film advanced, the product feedmechanism 150 operates to fill each base pocket 108 to a desired levelwith one or more product components such as a liquid, a gel, or powdereddetergent or other material. Traditionally, the size of the fill volumedefined by the base pocket exceeds the volume of the delivered productcomponent by about ten (10) percent.

As the pockets 108 in the base film 102 are being formed and filled, thelid film 104 is fed from its supply roll and passes around lid filmsealing roller 172. The lid film 104 is wetted by the lid wetting system160. In doing so, water or another solvent may be applied to the lidfilm 104 and the film becomes sufficiently tacky to ensure securing thelid film 104 to the base film 102 along the overlying portions of thefilm to form sealed interface 106.

The film sealing roller 172 applies pressure and forces the base film102 and the lid film 104 into contact with sufficient pressure to causethe two films to bond together at the seal interface 106 and seal thepockets 110 and form the pouches 100. The lid film 104, positioned inoverlying relation to the base film 102 containing base pockets 108filled with a desired composition or product. The lid film 104 isforcibly engaged with the base film 102 by sealing roller 172 actingagainst smooth surface 122 surrounding each mold configuration 120 toseal the films together along perimeter seal seam 111 and form completedcontainment pouches 100. The films adhere to each other in areas wherethey are in contact at seal interface 106. Consequently, the perimeterseal seam 111 of the sealed pouch replicates the shape of the perimeteredge 126 of mold configuration 120.

The combined base film 102 and lid film 104 continues to advance aroundthe base forming drum 119 until reaching the cutting system 180.Slitting knives 181 and rotary knife 182 cut the combined films into theindividual pouches 100, having a surrounding rectangular flange 118. Theindividual pouches 100 are discharged onto conveyor 190 for furtherprocessing.

FIG. 3 illustrates the shape of pouch 100 of FIGS. 1 and 2 after fillingwith product and sealing of base pocket 108 with lid film 104, butbefore it is removed from the mold cavity 120. As is well known, afterrelease of the completed pouch from the mold cavity, internal pressureand the memory of the formed film causes it to try to return to itsunstretched state and the pouch assumes the bulbous or “blister” shapeseen in FIG. 2.

FIG. 4 illustrates a single mold configuration 120 that defines a moldcavity to form pocket 108 of base film 102. The mold configurationillustrated in FIG. 4 is approximately 1-⅞ inches long (transversely),1-⅜ inches wide (longitudinally) and ⅝ inches deep. As explained,multiples of such mold configurations 120 are formed into the smoothfilm support surface 122 defined by long bars 121 of base forming drum119. In this way multiple pouches are formed simultaneously. Moldconfiguration 120 is generally rectangular to produce the pouch 100 ofFIGS. 1-3. Of course, the shape is merely illustrative. Numerous otherpouch shapes are known, and produced.

The mold configuration 120 defines a void or cavity extending inwardfrom a perimeter edge 126 at smooth film support surface 122 of the baseforming drum 119. The maximum depth of the cavity is defined by a bottomwall surface 128. Bottom wall surface 128 includes a number of vacuumports 133 in communication with conduits 132 to create the vacuum ornegative pressure within the mold configuration 120.

The illustrated mold configuration 120 includes four straight side wallsurfaces 124 joined by curved transition wall surfaces 125 extending tobottom wall surface 128 from perimeter edge 126. The side wall surfaces124 and transition wall surfaces 125 extend inward of perimeter edge 126perpendicular to, or at a slight relief angle to, smooth film supportsurface 122.

The perimeter edge 126 is comprised of side edge portions 126S andtransition edge portion 126T. The perimeter edge side edge portions 126Srepresent the intersection of side wall surfaces 124 with smooth filmsupport surface 122 and, in this conventional mold configuration, theperimeter edge transition edge portions 126T represent the intersectionof transition wall surfaces 125 with smooth film support surface 122.The transition wall surfaces 125 are typically formed on a relativelylarge radius, about ⅜ inch or more. The side wall surfaces 124 andtransition wall surfaces 125 join bottom wall surface 128 at a radiusfillet 129, generally about ⅜ inch, to define a fill volume for basepocket 108 sufficient to receive product component 110.

Referring to FIG. 1, perimeter seal seam 111 of pouch 100 includes sideseal seam portions 112 and corner seal seam portions 114 having a radiusdefined by the shape of transition edge portion 126T. The pouch shapethus replicates the relatively large radii of transition wall surfaces125 of mold configuration 120 at transition edge portions 126T.

In FIG. 11, the imaginary lines “ST” indicate the demarcation betweenside wall surfaces 124 and transition wall surfaces 125 and,coincidentally, side edge portions 126S and transition edge portions126T of perimeter edge 126. At lines ST, transition wall surfaces 125tangentially merge with side wall surfaces 124. It is, of course,understood that this marking is for ease of understanding and thatperimeter edge 126 is continuous and represents the perimeter definitionof mold configuration 120 at smooth film support surface 122.

The films 102 and 104 form a sealed interface 106 that extends laterallyfrom perimeter seam 111 of each completed pouch 100. That is, noadherence between films occurs over the void area where film 104overlies base film 102 over pocket 108 represented by the cavity of moldconfiguration 120 within perimeter edge 126.

Pouches formed of polymeric material such as polyvinyl alcohol are proneto shrinkage and distortion after forming, filling and sealing. Whenlocated in mold cavity 120, the applied vacuum through ports 133 retainsthe shape illustrated in FIG. 3. Once released, however, the pouch basepocket 108 shrinks to a smaller volume, sometimes up to twenty or morepercent (20%) smaller. Because the pouch 100 is sealed, the shrinkage isaccommodated with stretching of lid film 104 to form the shape shown inFIG. 2. Often lid film 104 is a thinner material than base film 102 toaugment the expansion characteristic of lid film.

In the thermoforming process, the film 102 is drawn into the mold cavityof the mold configuration. The film in the center of the pouch form isdrawn down into contact with the bottom wall surface 128 of the moldconfiguration 120. When the film contacts bottom surface 128, heatdissipates and the film essentially ceases to stretch further. After thefirst contact of the film to the bottom wall surface 128 of the moldcavity, the film continues to be drawn into contact with the othersurfaces of the mold configuration. Only the film that has not yetcontacted the bottom surface of the mold configuration 120 continues tostretch spreading out over the bottom surface 128 until it is in contactwith the entire cavity defining surfaces, including side wall surfaces124 and transition wall surfaces 125. The film that contacts the moldconfiguration last is the film that has been stretched the most and isthe thinnest film. It is the film at the radius fillet 129 overlying thejunction of the bottom wall surface 128 of the mold cavity with the fourside wall surfaces 124 and the four transition wall surfaces 125 asillustrated in FIG. 4.

The shape of the mold configuration 120, particularly the transitionedge portions 126T of perimeter edge 126 and the relatively large radiusof transition wall surfaces 125, is intended to provide for uniformdeformation or stretch of the base film 102 during vacuum forming.Optimally, film stretch is maintained within the established guidelinesof no greater than two times the pre-stretched area of film overlyingthe mold configuration cavity. Excessive stretching or thinning of thedeformed film that causes weak areas in the formed pouch, which couldresult in failure and/or leakage is avoided.

All of the above-described machinery and processing steps are well knownin the art. The purpose here was to explain the limitations inherent inmanufacturing that have heretofore dictated the shape of the formedpouches. It has, and continues to be necessary, to avoid unduestretching or thinning of the polymeric films as it is processed. Moldconfigurations, such as mold configuration 120 of FIG. 4, requirerelatively large radii along perimeter edge 126 to form the transitionbetween film support surface 122 and the mold cavity defined by sidewall surfaces 124 and transition wall surfaces 125 to control filmdeformation or stretch during forming.

The remainder of this description is directed to the concepts of thisdisclosure, which overcome the above-described limitations as well asobviating the need for long tapering transitions with low volumecapacity. In accordance with this disclosure, pouches can be formed withsharp definition, i.e., sharp corner profiles, without sacrifice ofstrength of the film, or integrity of the formed pouches. Moreover, itis contemplated that the approach of this disclosure greatly simplifiesthe design and manufacture of mold configurations to create sharplydefined shapes for polymeric pouches formed by vacuum forming.

Application of the principles of this disclosure provides the capabilityto form flexible, sealed pouches of consumable product configured topresent a sharp corner profile. The term “sharp corner profile” is usedhere with reference to the shape of the mold configuration perimeteredge, and the shape of the resultant pouch seal seam. A sharp cornerprofile is defined by lines or surfaces, generally straight or slightlycurved, that meet at an intersection or vertex to form an angle. Theprinciples disclosed herein are considered beneficial to corner profileshaving a radius as large as about 7 mm (0.28″). In employing suchprinciples, corner profiles having a radius as small as about 1 mm(0.004″) can be achieved. Accordingly, the term sharp corner profile isintended to embrace this entire spectrum. As will be described below,there may be more than four sharp corner profiles defined by a moldconfiguration perimeter edge or the seal seam of a resultant pouch.

An exemplary flexible product containing pouch with sharp cornerprofiles, designated 200, is illustrated in FIGS. 8-10. It is but onesuch pouch embodiment. The specific shape is not a limitation onapplication of these principles. Numerous and varied shapes andconfigurations of pouches may be created which embody the conceptsdisclosed.

Pouch 200 includes a base film 202 defining base pocket 208 and a lidfilm 204 joined along a seal interface 206, forming surrounding flange218. It includes a hollow interior volume defined by perimeter seal seam211 containing a product component 210, in this illustration, a liquid.Of course, any other desired product component is suitable to the pouchproduced in accordance herewith.

The perimeter seal seam 211 includes generally straight perimeter sideseal seam portions 212 joined by corner seal seam portions 214 that, inaccordance with this disclosure, define a sharp corner profile.

FIGS. 6 and 7 illustrate a mold configuration 220 for producing thepouch 200 of FIGS. 8-10. Mold configuration 220 defines a mold cavityextending inward from smooth film support surface 222 of a long bar 221,multiples of which form a base forming drum similar to the drum 119 ofFIG. 5.

The mold cavity of mold configuration 220 extends inward of smooth filmsupport surface 222 from perimeter edge 226. It includes four side wallsurfaces 224 joined by four transition wall surfaces 225 that extend toa bottom wall surface 228 at a generous radius fillet 229, about ⅜inches. The bottom wall surface 228 includes a number of vacuum ports233 in communication with conduits within the rotary drum to create avacuum or negative pressure within the mold configuration 220. Ingeneral, these features of the mold configuration parallel the moldconfiguration 120 of known design, seen in FIG. 4.

In accordance with this disclosure and as seen in FIG. 6, the perimeteredge 226 of the mold configuration differs significantly from perimeteredge 126 of the conventional mold configuration 120 illustrated in FIG.4. Here, perimeter edge 226 includes side edge portions 226S joined bysharp corner edge portions 226C.

Sharp corner edge portions 226C are defined by the intersection ofinward edge surfaces 227 with smooth film support surface 222. Inwardedge surfaces 227 are disposed in a sharp corner profile and extendinward from perimeter edge 226 of the mold cavity perpendicular, or at aslight relief angle, to smooth film support surface 222 to plateausurfaces 230. In this regard, inward edge surfaces 227, at perimeteredge 226 of mold configuration 222 define lines (sharp corner edgeportions 226C) that are generally straight and meet at an intersectionor vertex to form an angle within the sharp corner profile definitionpreviously set forth.

It should be understood that the inward edge surfaces 227 need not beperpendicular to smooth film support surface 222. It is only necessarythat the inward depressions to plateau surfaces 230 be such that duringdeformation of the base film, no excessive or uneven stretching orthinning occur.

In particular reference to FIGS. 6 and 7, the plateau surfaces 230present relieved areas in each corner of the mold configuration 220,adjacent sharp corner perimeter edge portions 226C, but spaced inwardlyfrom the smooth film support surface 222. The inward spacing of theplateau surfaces 230 relative to the smooth film support surface 222 ofthe drum, represents the inward length of inward edge surfaces 227. Theinward spacing of the plateau surfaces 230 relative to the smooth filmsupport surface 222 forming relieved areas is limited to permit the basefilm at those areas to be deformed or stretched only a relatively smallamount below or inward from the smooth film support surface 222 duringvacuum forming of the base film into the cavity of the moldconfiguration 220. This minimal stretching or deformation ensures theintegrity of the base film 202, even though that stretching ordeformation occurs in a sharp corner profile represented by sharp corneredge portions 226C. Importantly, the inward length of inward edgesurfaces 227 should also be adequate to ensure that the lid film 204 andbase film 202 do not adhere together in the areas overlying the plateausurfaces 230. It, for example, may be approximately 2 mm (0.08″). Ingeneral, the plateau surfaces 230 at the four corners of the moldconfiguration 220 may be from 1 to 6 mm (0.04 to 0.24″) inward or belowthe smooth surface film support surface 222.

The plateau surfaces 230 need not be planar or parallel to the smoothfilm support surface 222 of the drum or to each other. They could beformed, for example, at an angle extending inwardly from the inward edgesurfaces 227. It is only necessary that the plateau surfaces 230 bespaced inward of the smooth film support surface 222 so as to ensureminimal deformation or stretching of base film in these locations duringvacuum forming and also provide sufficient spacing between base film 202and lid film 204 during pouch closure such that the lid film 204 doesnot adhere to the base film 202 at these locations.

As best seen in FIG. 6, mold configuration 220 includes, as in theinstance of mold configuration 120 of FIG. 4, curved transition wallsurfaces 225 that join generally straight side wall surfaces 224.However, in this embodiment, transition wall surfaces 225 definetransition edge portions 226T at the juncture of transition wallsurfaces 225 with plateau surfaces 230.

The mold configuration 220 side wall surfaces 224 and transition wallsurfaces 225, along with bottom wall surface 228 and radius fillet 229,define a fill volume for base pocket 208 to receive the productcomponent. Hence, this fill volume is inward of plateau surfaces 230,though that is not essential. As in the conventional mold configuration120 of FIG. 4, the fill volume may exceed the volume of the productcomponent 210 by about ten percent (10%). Notably, the configuration ofthe side wall surfaces 224, transition wall surfaces 225 bottom wallsurface 228 and radius fillet 229 represent a mold cavity configurationdesigned to ensure proper film stretch or deformation in accordance withconventional forming principles.

In FIG. 12, the imaginary lines “ST” indicate the demarcation betweenside edge portions 226S and sharp corner edge portions 226C of perimeteredge 226 of mold configuration 220, seen in FIG. 6. Also, at lines ST,curved transition wall surfaces 225 tangentially merge with side wallportions 224. Notably, each inward edge surface 227 extends alongperimeter edge 226 from the corner intersection (vertex) with itsassociated inward edge surface 227 to the transition between associatedside wall surfaces 224 and transition wall surfaces 225. As seen in FIG.12, inward edge surfaces 227 merge or seamlessly blend into side wallsurfaces 224 at imaginary lines ST.

Perimeter edge 226 is continuous and represents the perimeter definitionof mold configuration 220, in accordance with this disclosure. As in theknown mold configuration of FIG. 4, the perimeter edge 226 of the moldconfiguration 220 of FIGS. 6 and 7, defines the shape of the formedpouch. As in the known pouch of FIGS. 1-3, the perimeter edge 226 of themold configuration 220 of FIG. 4 defines the perimeter seal seam 211between the base film 202 and lid film 204 on formation of a completedpouch 200. Since the perimeter edge 226 sharp corner edge portions 226Tpresent a sharp corner profile, the resultant pouch 200 presents thatsame shape, as illustrated in FIG. 8.

In accordance with the disclosure, the pouch forming mold configuration220 in the base film smooth support surface 222 has a generallyrectangular perimeter edge 226. That is, as seen in FIG. 6, all cornersof the mold configuration 220 are formed with sharp corner profiles.These corner profiles are defined by the intersection of the inward edgesurfaces 227 defining the mold cavity and the smooth film supportsurface 222 of the drum surrounding the mold cavity. Here, straightlines defined by inward edge surfaces 227 intersect at a vertex anddefine corners having an angle of 90° (degrees). This angle is not,however, essential. The lines defining the sharp corner profile mayintersect at angles greater, or smaller, than 90°, as illustrated infurther embodiments described below and shown in FIGS. 15-18.

Manufacture of pouches such as illustrated in FIGS. 8-10, proceeds as inthe manufacture of pouches illustrated in FIGS. 1-3. However, the rotarydrum or platen of the form, fill and seal machine is provided with moldconfigurations 220 as illustrated in FIGS. 6 and 7. When the base filmis drawn into the mold cavity of a mold configuration 220 and forms basepocket 208 illustrated in FIG. 10, the base film overlying the relievedareas at plateau surfaces 230 is drawn inward and below the smooth filmsupport 222 surface of the drum only to a level of plateau surfaces 230.This depth is shallow enough to prevent any excessive stretching orthinning of the film in this area. While not considered essential to theprocess, the plateau surfaces 230 may also have vacuum ports 235 toensure contact of base film with these surfaces. This option isillustrated in FIG. 6.

The balance of the base pocket 208 is drawn into the mold cavity definedby side wall surfaces 224, transition wall surfaces 225, radius fillet229 and bottom wall surface 228 in accordance with known methods. Thebase film remains at an adequate thickness to form a functional basepocket 208 defining a fill volume that is adequately sized, durable anddoes not leak from over-stretching of the film.

On filling, the formed base film pocket shape receives about 90% of itscapacity. As depicted in FIG. 10, the consumable product material mayreside only in the fill volume of the pocket defined by side wallsurfaces 224, transition wall surfaces 225, the bottom wall surface 228and radius fillet 229, but not the plateau surfaces 230, though this isnot essential. That is, some amount of the product component 210 mayinitially be disposed on film 202 at plateau surfaces 230. Importantly,the film in the relieved areas overlying plateau surfaces 230 is belowthe smooth film support surface 222 of the drum. On completion of apouch, the base film 202 and lid film 204 are not adhered together inthe relieved areas.

When the pouch 200 is filled and sealed with an overlying lid film 204,the pouch 206 will take on the shape dictated by the cavity perimeteredge 226 at the surface 222 of the mold configuration 220. Pouch 200will thus present sharp corner profiles defined by perimeter edge 226.In this regard, the seal seam 211 sharp corner seal seam portions 214form right angles (90°). Imaginary indicator lines designated I, areshown in FIG. 8 to indicate the demarcation of sharp corner seal seamportions 214.

As previously explained with regard to the pouch 100 of FIGS. 1-3, onrelease from the mold configuration, the pouch conforms to the shapeillustrated in FIG. 9 as a result of the well-known shrinkage of thebase film and complementary stretch or expansion of the lid film. Thefilms 202 and 204 used to produce pouches 200 may be similar incomposition and thickness to those used to produce pouches 100.

The result of the above-described modification to the mold configuration220 of FIGS. 6 and 7 as compared to the mold configuration 120 of FIG.4, is evidenced by comparison of the pouch 100 of FIGS. 1-3 and thepouch 200 of FIGS. 8-10. Importantly, the perimeter seam seal 211between the base film 202 and lid film 204 defines sharp cornerprofiles. This shape derives from the spacing or separation between thefilms where they overlie the plateau surfaces 230 during the compressionpressured sealing of the films. The films do not contact each othersufficiently to adhere at the portions of the pouch films overlying theplateau surfaces 230. Consequently, the films form additional internalpouch volume, extending to the perimeter seal seam 211.

The embodiment of FIGS. 6-10 illustrates a mold configuration and pouchwith four corners presenting sharp corner profiles. The embodiments ofFIGS. 13,15 and 16-19 are illustrative of mold configurations andpouches with numerous sharp corner profiles, each with sharp definition.

FIG. 14 illustrates a star shaped pouch 500 formed using conventionalmold configuration principles, that is, without sharp corner profilesformed in the perimeter edge of the mold configuration. The pouchconsequently has a perimeter seal seam 511 with rounded corners 503 thatreplicate the perimeter edge of the mold configuration used to producethe pouch.

FIG. 13 illustrates a mold configuration 320, in accordance with thedisclosure, for making a star-shaped pouch 300 having sharp cornerprofiles as seen in FIG. 15. Pouch 300 has a base film formed by vacuumforming into a base pocket to which is sealed a lid film 304 to formflange 318 of adhered films. The pouch configuration is defined byperimeter seal seam 311 and contains a product component 310. Itincludes multiple star point shaped facets 317 defined by sharp cornerprofiles.

Perimeter seal seam 311 includes corner seal seam portions 314A and314B, respectively, defining acute and obtuse angles (as viewed fromwithin pouch 300) all presenting sharp corner profiles. Indicator linesperpendicular to seal seam 311 (designated I) are present in FIG. 15 toshow the demarcation between these elements of the seal seam. Eachassociated pair of corner seal seam portions 314A meet at anintersection or vertex defining an acute angle. These corner seal seamportions form the points of the star shaped pouch 300. Similarly, eachassociated pair of corner seal seam portions 314B meet at anintersection or vertex to form an obtuse angle at the base of each starpoint facet. The slightly convex seal seam portion 314A and slightlyconvex seal seam portion 314B tangentially merge into each other midwaybetween the sharp corner profiles (at imaginary lines I) to define thecomplete perimeter seal seam 311. These slightly curved lines, someconvex (314A), some concave (314B) when viewed from inside pouch 300 areintended to improve the aesthetic qualities of pouch 300.

The mold configuration illustrated in FIG. 13, defines a mold cavityextending inward from a smooth film support surface 322 of a rotary drumor movable platen. It includes transition wall surfaces 325, joined to abottom surface 328 by a relatively generous radius fillet 329,illustrated as about ⅜ inch. These surfaces define a fill volume toreceive the pouch product content. This structure of mold configuration320 is consistent with conventional mold configuration practices toavoid undesirable stretching or thinning of the pouch film duringforming.

Mold configuration 320 extends inwardly of smooth film support surface322 from perimeter edge 326, which includes a plurality of sharp cornerprofiles defined by corner edge portions 326A and 326B. The demarcationbetween edge portions 326A and 326B is identified in FIG. 13 byimaginary lines designated I.

Sharp corner edge portions 326A and 326B are defined by the intersectionof inward edge surfaces 327 with smooth film support surface 322. Theseedge portions extend inwardly perpendicular to smooth film supportsurface 322 to plateau surface 330. They define sharp corner edgeportions 326A, which meet at an intersection or vertex to form an acuteangle. They also define sharp corner edge portions 326B, which meet atan intersection or vertex to form an obtuse angle. Both these angles arewithin the sharp corner profile definition previously set forth.

As illustrated in connection with the mold configuration illustrated inFIGS. 6 and 7, sharp corner edge portions 326A and 326B are formed byinward edge surfaces 327. Inward edge portions 327 extend betweenperimeter edge 326 at smooth film support surface 322 and plateausurfaces 330, which are disposed inward of film support surface 322 onlyan amount sufficient to avoid adherence of the lid film 304 and basefilm on closure of the pouch.

The mold configuration 320 includes relieved areas at plateau surfaces330 associated with each sharp corner profile to reduce film stretchingand stress on the film during forming. Notably, in this embodiment, theplateau surface 330 at each sharp corner profile merges with the plateausurface of adjacent sharp corner profiles thereby forming a continuousplateau surface 330 coextensive with the perimeter edge 326.

The plateau surface 330 meets the smooth radius transition wall surfaces325 of the mold configuration 320 at transition edge portions 326T (seeFIG. 13). Plateau surface 330 is only spaced from the smooth filmsupport surface 322 an amount sufficient to permit deformation of thebase film inward of the mold cavity within the accepted guidelines offilm deformation. Such spacing may usually be from about 1.0 mm (0.04″)to about 6 mm (0.24″) depending on film thickness, pouch size and otherfactors.

Moreover, on application of the lid film, which for PVA films normallyhas been wetted or otherwise made “sticky,” the resultant spacingbetween films avoids contact in the relieved areas associated with theplateau surfaces 330. The perimeter edge 326 at the smooth film supportsurface 322 defines the perimeter seam of the two films creating a pouchwith sharp corner profiles as illustrated in FIG. 15. This sharp cornerprofile pouch represents a striking enhancement over a star shaped pouchas illustrated in FIG. 14. There, because the rounded transition wallsurfaces of the mold configuration extend to the perimeter edge, thestar pouch perimeter seal seam 511 is also rounded.

It is also important to note that a mold configuration with sharp cornerprofiles but without plateau surfaces 330 disposed inward of theperimeter edges 326 to limit film stretch at those areas would result inexcessive stretching or thinning of the base film in the sharp cornersand lead to tears and/or leakage. This consequence is avoided by theprinciples of this disclosure.

It is contemplated that as disclosed herein, a wide variety of desiredpouch shapes can be created employing relieved areas adjacent theperimeter edge of a mold configuration with sharp corner profiles. Thatis, the shape of the perimeter edge for a mold configuration may includesharp corner profiles, so long as there is also provided a plateausurface associated with the sharp corner profiles that; 1) limitsdeformation or stretch of the base film on application of vacuum to drawit into the mold cavity and 2) is sufficiently spaced from the smoothfilm support surface of the base forming drum to avoid adherence betweenthe base film and lid film at these locations. Such relieved areas areaccomplished by providing inward edge surfaces that extend to plateausurfaces within a cavity defined by a mold configuration, as described.

The plateau surfaces adjoin a central product fill volume or cavitydefined by a bottom wall surface 328 with a radius fillet 329 to largeradius transition wall surfaces 325, within which the base film isformed to conventional stretch guidelines. The fill volume or cavity hassufficient capacity to receive the desired quantity of product componentto be packaged. The relieved areas at the plateaus provide spacingbetween the base film and lid film to ensure minimal stretch duringforming and insufficient contact in those areas to prevent adherencebetween the films on sealing of the pouches being formed.

A further example of the versatility of the principles disclosed hereinis illustrated by the mold configuration and resultant pouch of FIGS.16-19. In accordance with the disclosure, a multi-chamber pouch 400having sharp corner profiles is shown in FIGS. 16-18. The moldconfiguration for creating pouch 400 is shown in FIG. 19.

Pouch 400 has a base film 402 formed by vacuum forming into a basepocket 408 to which is sealed a lid film 404 to form flange 418. It hasmultiple chambers, separated along a central web 403 best seen in FIG.17. Base film 402 and lid film 404 are adhered together at centraldivider 403 as in flange 418. The pouch shape is defined by perimeterseal seam 411 about each chamber defining sharp corner profiles andcontains a product component 410 within the formed pouch chambers.

Perimeter seal seam 411 includes corner seal seam portions 414A and414B, formed of slightly curved lines, respectively, defining acute andobtuse angles (as viewed from within pouch 400) all presenting sharpcorner profiles. Imaginary indicator lines (designated I) perpendicularto seal seam 411 are seen in FIG. 17, that show the demarcation betweenthese elements of the seal seam. Of course, corner seal seam portions414A and 414B could be formed by straight lines.

Corner seal seam portions 414A and 414B merge together at imaginaryindicator lines I. In this embodiment, each associated pair of cornerseal seam portions 414A or 414B meet at an intersection or vertex toform an angle. The combined corner portions 414A and 414B of seal seam411 present the multiple chamber pouch configuration with multiple sharpcorner profiles.

Mold configuration 420 of FIG. 19 is illustrative of plateau surfaces,designated 430, disposed inward of smooth film support surface 422,defining relieved areas employed in a multi-chamber mold configuration.Mold configuration 420 defines separate voids or cavities 420A and 420Bextending from a perimeter edge 426 at smooth outer film support surface422 of a long bar 419, as explained, a part of a base forming drum suchas seen in FIG. 5. In this instance, the mold configuration includes acentral divider 422C defined by smooth film support surface 422 of baseforming drum long bar 419. This divider could be formed with straightline edges as has been the case in prior multi-chamber pouches, or itcould be scalloped or some other desired shape.

Each separate chamber 420A and 420B of mold cavity of mold configuration420 extends inward of smooth film support surface 422. It includes sidewall surfaces 424 joined by transition wall surfaces 425 that extend toa bottom wall surface 428 at a generous radius fillet 429, about ⅜inches. The bottom wall surface 428 includes a number of vacuum ports433 in communication with conduits within the rotary drum to create avacuum or negative pressure within the mold configuration 420. Ingeneral, these features of the mold configuration parallel the moldconfiguration 120 of known design, seen in FIG. 4.

As in the embodiment of the mold configuration 220 of FIGS. 6 and 7, andthe mold configuration 320 of FIG. 11, the perimeter edge 426 of moldconfiguration 420 defines the perimeter seal seam 411 joining the basefilm 402 and lid film 404 to complete a multi-chamber pouch 400. Here,the multiple compartments of a single pouch 400 are created by adherenceof the lid and base films along central divider 422C.

Chambers 420A and 420B of mold configuration 420 extend inwardly ofsmooth film support surface 422 from perimeter edge 426, which includesa plurality of sharp edge profiles defined by corner edge portionsindicated generally as 426A and 426B in FIG. 19. Sharp corner edgeportions 426A and 426B are defined by the intersection of inward edgesurfaces 427 with smooth film support surface 422. These edge portionsextend inwardly perpendicular to smooth film support surface 422 toplateau surface 430 and are slightly curved, though they could bestraight.

Sharp corner edge portions 426A meet at an intersection or vertexdefining an acute angle and sharp corner edge portions 426B meet at anintersection or vertex defining an obtuse angle, each within the sharpcorner profile definition previously set forth. The sharp corner edgeportions 426A and 426B merge to define continuous perimeter edge 426around each separate cavity 420A and 420B.

Relieved areas within mold configuration 420 are defined by plateausurface 430 inward of the smooth film support surface 422. In thisembodiment, plateau surface 430 is continuous about the perimeter edge426. It is spaced inward of smooth film support surface 422 only adistance sufficient to permit minimal deformation or stretching of thebase film 402 at these areas. It is also spaced inward sufficiently toavoid adherence of the base film 402 and lid film 404 on pouchformation.

The remainder of the mold configuration cavity is defined by side wallsurfaces 424 and transition wall surfaces 425 joined to a bottom wallsurface 428 by a generous radius fillet 429. These surfaces extend fromtransition edge portions 426T at the juncture with plateau surface 430.They define the fill cavity inward from plateau surface 430, though itis not essential that the fill volume be completely below the plateausurfaces.

Utilization of the plateau surface 430 adjacent, but spaced inwardlyfrom smooth film support surface 422 at the perimeter edge 426 of themold configuration 420 provides the capability to create complexperimeter seams and consequently complex pouch shapes without excessivestretch or thinning of the pouch forming base film overlying the plateausurface during forming. The plateau surface provides relieved areas withsufficient spacing between the facing surfaces of the base film 402 andlid film 404 to prevent adherence where the films overlie the relievedareas. Hence, the perimeter seal seam 411 follows the perimeter edge 426of the mold configuration 420, as has been explained.

Understandably, as illustrated by the embodiment of FIGS. 16-19, theprinciples disclosed herein apply to creation of pouches having morethan one product compartment. The important feature is the interpositionof plateau surfaces 430 within the mold cavity adjacent the perimeteredge 426 of the mold configuration 420 to provide relieved areasadjacent the sharp corner profiles. The remainder of the moldconfiguration portions define the fill chamber in accordance withconventional mold design principles to receive the product component tobe packaged.

The inwardly spaced plateau surfaces 430 ensure minimal deformation ofthe film during base pocket formation and prevents undue stretching orweakening of the film. The plateau surface 430 is also significant inthe pouch forming process in that they represent relieved areas wherethe base film and overlying lid film will not adhere together duringpouch completion. The pouch internal volume is thus defined by theperimeter edge of the mold configuration 426 at the smooth outer filmsupport surface 422, with the separated films overlying the plateausurfaces adding or contributing to the overall internal pouch volume.

The foregoing embodiment is another example of the versatility of themechanisms and methods disclosed herein. The principles disclosedprovide for manufacture of new and aesthetically pleasing pouch shapeswithout sacrifice in pouch strength. Moreover, it is contemplated thatthis capability will lead to pouch shapes not previously possible.

It is contemplated that the principles disclosed here are not limited toforming pouches with sharp corner profiles. Relieved areas in the moldconfiguration adjacent the perimeter edge, defined by inwardly disposedplateau surfaces can be employed to form any shape pouch perimeter. Theperimeter edge of the mold configuration defines the perimeter seambetween joined films and consequently the pouch shape. Inwardly disposedplateau surfaces forming relieved areas adjacent these perimeter edges,surrounding, or partially surrounding, a central fill cavity of the moldconfiguration may be employed to minimize film deformation, stretch orweakening in any pouch configuration by limiting film stretch, whilealso permitting film spacing sufficient to avoid adherence between thefilms in these areas during closure or completion of the formed pouch.

It will be appreciated that the foregoing description provides examplesof the disclosed system and techniques. However, it is contemplated thatother implementations of the disclosure may differ in detail from theforegoing examples. All references to the disclosure or examples thereofare intended to reference the particular example being discussed at thatpoint and are not intended to imply any limitation as to the scope ofthe disclosure more generally. All language of distinction anddisparagement with respect to certain features is intended to indicate alack of preference for those features, but not to exclude such from thescope of the disclosure entirely unless otherwise indicated.

Recitation of ranges of values herein are merely intended to serve as ashorthand method of referring individually to each separate valuefalling within the range, unless otherwise indicated herein, and eachseparate value is incorporated into the specification as if it wereindividually recited herein. All methods described herein can beperformed in any suitable order unless otherwise indicated herein orotherwise clearly contradicted by context.

Accordingly, this disclosure includes all modifications and equivalentsof the subject matter recited in the claims appended hereto as permittedby applicable law. Moreover, any combination of the above-describedelements in all possible variations thereof is encompassed by thedisclosure unless otherwise indicated herein or otherwise clearlycontradicted by context.

1. A mold configuration for forming a pocket in a base film of apressurized product containment pouch having a base film and a lid filmadhered about a perimeter seal seam comprising: a film support surface;perimeter edge at said film support surface; wall surfaces extendinginward from said perimeter edge defining a mold cavity; said wallsurfaces including a bottom wall surface and transition wall surfacesextending to said bottom wall surface; and at least one plateau surfacewithin said mold cavity, inward of said perimeter edge; wherein said atleast one plateau surface is spaced inward of said film support surfacea distance sufficient to prevent adherence of the lid film to the basefilm overlying said at least one plateau surface.
 2. A moldconfiguration for forming a pocket in a base film as claimed in claim 1,wherein said perimeter edge includes sharp corner profile perimeter edgeportions defining at least one sharp corner profile; and said wallsurfaces include inward edge surfaces that extend between said sharpcorner profile perimeter edge portions and said at least one plateausurface of said at least one sharp corner profile.
 3. A moldconfiguration for forming a pocket in a base film as claimed in claim 2,wherein one of said transition wall surfaces extends between said bottomwall surface and said plateau surface of said at least one sharp cornerprofile.
 4. A mold configuration for forming a pocket in a base film asclaimed in claim 3, wherein said sharp corner profile perimeter edgeportions defining said at least one sharp corner profile are straight orslightly curved, and meet at an intersection or vertex.
 5. A moldconfiguration for forming a pocket in a base film as claimed in claim 3,wherein said perimeter edge includes plural sharp corner profileperimeter edge portions defining plural sharp corner profiles, each saidsharp corner profile including a plateau surface inward of said sharpcorner profile perimeter edge portions.
 6. A mold configuration forforming a pocket in a base film as claimed in claim 5, wherein inwardedge surfaces extend between said sharp corner profile perimeter edgeportions and said plateau surfaces of each said sharp corner profiles.7. A mold configuration for forming a pocket in a base film as claimedin claim 6, wherein a transition wall surface extends between saidbottom wall surface and said plateau surface of each said sharp cornerprofiles.
 8. A mold configuration for forming a pocket in a base film asclaimed in claim 7, wherein said wall surfaces further include side wallsurfaces extending inward from said perimeter edge and merging with saidtransition wall surfaces, and said side wall surfaces, transition wallsurfaces and bottom wall surface defining a fill volume sized to receivea delivered product component.
 9. A mold configuration for forming apocket in a base film as claimed in claim 6, wherein said plateausurfaces are disposed relative to the perimeter edge such as to limitelongation of the base film into the mold configuration from the filmsupport surface to no more than twice its original area.
 10. A moldconfiguration for forming a pocket in a base film as claimed in claim 6,wherein said sharp corner profiles include sharp corner edge portionsdefining acute and obtuse angles.
 11. A mold configuration for forming apocket in a base film as claimed in claim 6, wherein said plateausurface is continuous about said perimeter edge.
 12. A moldconfiguration for forming a pocket in a base film as claimed in claim 7,wherein said inward edge surfaces of each sharp corner profile aredisposed at ninety degrees (90°) to each other.
 13. Apparatus forforming a pressurized product containment pouch from a base film and alid film adhered about a perimeter seal seam comprising: mechanismincluding a film support surface having at least one mold configurationtherein, for forming a pocket in the base film comprising: a perimeteredge at said film support surface; wall surfaces extending inward fromsaid perimeter edge defining a mold cavity; said wall surfaces includinga bottom wall surface and transition wall surfaces; extending to saidbottom wall surface, and at least one plateau surface within said moldcavity inward of said perimeter edge, wherein said at least one plateausurface is spaced inward of said film support surface a distancesufficient to prevent adherence of the lid film to the base filmoverlying said at least one plateau surface, mechanism supplying a basefilm onto said film support surface; mechanism applying a vacuum to saidmold configuration to cause said base film to form a pocket conformingto the shape of said mold cavity; mechanism for filling said pocket withat least one product component; mechanism for adhering a lid film to thebase film on said film support surface.
 14. The apparatus for forming apouch from film as claimed in claim 13, wherein said perimeter edgeincludes sharp corner profile perimeter edge portions defining at leastone sharp corner profile; and said wall surfaces include inward edgesurfaces that extend between said sharp corner profile perimeter edgeportions and said at least one plateau surface of said at least onesharp corner profile.
 15. The apparatus for forming a pouch from film asclaimed in claim 14, wherein one of said transition wall surfacesextends between said bottom wall surface and said plateau surface ofsaid at least one sharp corner profile.
 16. The apparatus for forming apouch from film as claimed in claim 15, wherein said perimeter edgeincludes plural sharp corner profile perimeter edge portions definingplural sharp corner profiles, each said sharp corner profile including aplateau surface inward of said sharp corner profile perimeter edgeportions.
 17. The apparatus for forming a pouch from film as claimed inclaim 14, wherein said mechanism including a film support surfacecomprises a rotatable base forming drum.
 18. A method of forming a pouchhaving at least one sharp corner profile, using a mold configuration forforming a pocket in a film comprising: a film support surface; aperimeter edge at said film support surface; wall surfaces extendinginward of said perimeter edge defining a mold cavity; said wall surfacesincluding transition wall surfaces extending to a bottom wall surface,said perimeter edge includes sharp corner profile perimeter edgeportions defining at least one sharp corner profile; and a plateausurface inward of said sharp corner profile perimeter edge portions; thesteps comprising: supporting a base film on said film support surfaceoverlying said mold configuration; applying a vacuum to said moldconfiguration to cause said base film to form a pocket conforming to theshape of said mold configuration; filling said pocket with at least oneproduct component; adhering a lid film to said base film laterally ofsaid perimeter edge of said mold configuration.
 19. A method of forminga pouch as claimed in claim 13, wherein: wherein said perimeter edgeincludes plural sharp corner profile perimeter edge portions definingplural sharp corner profiles, each said sharp corner profile including aplateau surface inward of said sharp corner profile perimeter edgeportions; wherein said plateau surfaces are spaced inward of said filmsupport surface a distance sufficient to prevent adherence of a lid filmto a base film overlying said plateau surfaces.
 20. A method of forminga pouch as claimed in claim 14, wherein during said forming step saidfilm overlying said plateau surfaces is stretched less than twice itsoriginal area.
 21. A method of forming a pressurized product containmentpouch having a base film and a lid film adhered about a perimeter sealseam using a mold configuration having a film support surface; perimeteredge at said film support surface; wall surfaces extending inward fromsaid perimeter edge defining a mold cavity; said wall surfaces includinga bottom wall surface and transition wall surfaces extending to saidbottom wall surface; and at least one plateau surface within said moldcavity, inward of said perimeter edge; wherein said at least one plateausurface is spaced inward of said film support surface a distancesufficient to prevent adherence of the lid film to the base filmoverlying said at least one plateau surface; the steps comprising:supporting a base film on said film support surface overlying said moldconfiguration; applying a vacuum to said mold configuration to causesaid base film to form a pocket conforming to the shape of said moldconfiguration; filling said pocket with at least one product component;adhering a lid film to said base film laterally of said perimeter edgeof said mold configuration.
 22. A method of forming a pouch as claimedin claim 21, wherein: wherein said perimeter edge includes plural sharpcorner profile perimeter edge portions defining plural sharp cornerprofiles, each said sharp corner profile including a plateau surfaceinward of said sharp corner profile perimeter edge portions.
 23. Amethod of forming a pouch as claimed in claim 22, wherein during saidstep of forming said base film, said film overlying said plateausurfaces is stretched less than twice its original area.